Automatic systems and methods for stacking composite plies

A method for making a stack of a plurality of composite plies, comprising:

• (i) providing one or more composite sheets between a layup tool and a plurality of stacking assemblies of an automatic layup system, wherein the plurality of stacking assemblies are located in a first plane of the automatic layup system and the layup tool is movable in a second plane parallel to the first plane to a plurality of positions aligned with the plurality of stacking assemblies, and wherein the plurality of stacking assemblies and the layup tool are movable towards each other;
• (ii) separating a first composite ply from the one or more composite sheets and placing the first composite ply on the layup tool by a first stacking assembly of the plurality of stacking assemblies by bringing the first stacking assembly and the layup tool close to each other when the layup tool is at a first position of the plurality of positions aligned with the first stacking assembly;
• (iii) moving the layup tool with the first composite ply to a second position of the plurality of the positions aligned with a second stacking assembly of the plurality of stacking assemblies;
• and
• (iv) separating a second composite ply from the one or more composite sheets and placing the second composite ply on the first composite ply placed on the layup tool by the second stacking assembly by bringing the second stacking assembly and the layup tool with the first composite ply close to each other.

An automatic layup system, comprising:

• at least one stacking assembly located in a first plane;
• at least one layup tool movable in a second plane parallel to the first plane to at least one position aligned with the at least one stacking assembly;
• and
• a support structure configured to hold a composite ply or a composite sheet between the at least one stacking assembly and the at least one layup tool,
• wherein the at least one stacking assembly comprises a positioning tool, and
• wherein the at least one stacking assembly and the at least one layup tool are movable towards each other.